BACKING PLATE FOR A DISK BRAKE OF A MOTOR VEHICLE AND METHOD FOR MANUFACTURING SAID BACKING PLATE

Abstract

The invention relates to a backing plate (1) for a disc brake of a motor vehicle, comprising a front side (2) for holding a friction lining. The backing plate (1) has a back side (3), on which a holding device (4) is arranged. The holding device is designed to hold a spring element (5), which consists of a spring base (6) and two spring legs (7, 8) arranged at the ends of the spring base (6). The holding device (4) is integrally bonded to the backing plate (1). The invention further relates to a method for producing a backing plate (1).

Claims

1. A backing plate (1) for a disc brake of a motor vehicle, comprising: a front side (2) adapted to accommodate a friction pad, a back side (3) opposite the front side (2), a mounting device (4) is-arranged on the back side (3) and integrally bonded to the backing plate (1), which mounting device (4) is adapted to accommodate a spring element (5) comprised of a spring base (6) and two spring legs (7, 8) arranged at the ends of the spring base (6).

2. The backing plate according to claim 1, wherein the mounting device (4) comprises at least one support element (9, 10, 11, 29, 30, 31) for the spring base (6) and each of the two spring legs (7, 8).

3. The backing plate according to claim 2, wherein at least one of the support elements (9, 10, 11, 29, 30, 31) has an undercut (13, 14, 33) in relation to the back side (3) of the backing plate (1) to accommodate the spring base (6) or a spring leg (7, 8) of the spring element (5).

4. The backing plate according to claim 2, wherein the mounting device (4) comprises a locking element (15) assigned to the support element (9) for the spring base (6).

5. The backing plate according to claim 2, wherein the mounting device (4) comprises a common support and guide element (18) for the two spring legs (7, 8) arranged on a longitudinal center axis (16) between a backing upper side (17) and the support elements (10, 11) of the two spring legs (7, 8).

6. The backing plate according to claim 1, wherein the backing plate is formed as a metal casting.

7. The backing plate according to claim 1, wherein the backing plate is formed as a steel plate, and wherein the mounting device (4) is formed by a progressive transfer process such as a punching process.

8. The backing plate according to claim 7, wherein the mounting device (4) comprises support elements (31) embodied as dimple-like projections (31) for supporting the spring legs (7, 8) and/or the spring base (6).

9. The backing plate according to claim 1, wherein the spring element (5) is formed as a wire spring.

10. A method for manufacturing a backing plate (1) according to claim 1, comprising the steps of: a. providing an at least two-part negative mold of a backing plate (1), which has a negative mold for the mounting device (4), b. providing a metal melt, c. closing the at least two-part negative mold of the backing plate (1), d. filling the at least two-part negative mold of the backing plate (1) with the melt, e. at least partially solidifying the melt within the closed negative mold of the backing plate (1), f. opening the negative mold of the backing plate (1), and g. removing the at least partially solidified backing plate (1).

11. The method according to claim 10, wherein at least one of the support elements (9, 10, 11, 29, 30, 31) for the spring base (6) and the two spring legs (7, 8) is provided with an undercut (13, 14), and wherein the undercut (13, 14) generated by milling out the at least one support element (9, 10, 11, 29, 30, 31).

12. The method according to claim 10 wherein the locking element (15) associated with the spring base (6) and/or the common support element (18) for the two spring legs (7, 8) is/are post-processed.

13. The method according to claim 10 wherein a spring element (5) is introduced into the mounting device (4).

14. A method for manufacturing a backing plate (1) according to claim 8, wherein the mounting device (4) of the backing plate (1) is formed with dimple-like projections (31) with undercuts (33) adapted as support elements (31), wherein the dimple-like projections (31) are formed by pushing through parts of the backing plate (1) to the back side (3) of the backing plate (1), and wherein the dimple-like projections (31) are formed in a forming process in a first step, and in that the dimple-like projections (31) are in a second step split and formed in the opposite direction to the forming process of the first step, so as to form the undercuts (33).

15. The method according to claim 14, wherein a rolled strip steel is used to manufacture the backing plate (1).

16. The backing plate according to claim 6, wherein the backing plate is formed as an iron casting.

Description

DESCRIPTION OF THE DRAWINGS

[0034] These show in:

[0035] FIG. 1 a first design example of an inventive backing plate in a top view of the back side,

[0036] FIG. 2 the backing plate of FIG. 1, into which a spring element is inserted,

[0037] FIG. 3 the backing plate of FIG. 1 with the spring element in its final position,

[0038] FIG. 4 a detailed view of the mounting device of the backing plate of FIGS. 1 to 3, and in

[0039] FIG. 5 a further detailed view of the mounting device of the backing plate of FIGS. 1 to 3

[0040] FIG. 6: a second design example of an inventive backing plate in a top view onto the back side,

[0041] FIG. 7 the backing plate of FIG. 6, into which a spring element is inserted,

[0042] FIG. 8 the backing plate of FIG. 6 with the spring element in its final position,

[0043] FIG. 9 a third embodiment according to FIGS. 6 to 8, but without support element,

[0044] FIG. 10 a fourth design example according to FIGS. 1 to 5, but without a support element,

[0045] FIGS. 11-13 a fifth design example of the backing plate with dimple-like projections and support elements,

[0046] FIG. 14 the embodiment according to FIGS. 11-13 as a cross-sectional representation by the cross-section line according to FIG. 11,

[0047] FIG. 15 a sixth design example of the backing plate with dimple-like projections, but without support elements,

[0048] FIG. 16 the embodiment according to FIG. 15 as a cross-sectional representation, and in

[0049] FIG. 17 the embodiment according to FIGS. 15 and 16 as an enlarged section of the representation according to FIG. 16.

DETAILED DESCRIPTION

[0050] FIG. 1 shows a backing plate 1 produced according to the inventive method in a top view of the back side. The backing plate 1 has a front side 2, onto which a friction pad can be applied, a back side 3, a backing plate top side 17 and a backing plate bottom side 24. A mounting device 4 for a spring element not shown in FIG. 1 is shown on the back side 3 of the backing plate 1. The mounting element 4 consists of a support element 9 for a spring base, two support elements 10 and 11 for respectively one spring leg, a common support element 18 for the spring legs, and a locking element 15 for the spring base. The locking element 15 also has an alignment slant 23 beyond which the spring base is pushed out when a spring element is inserted in order to come to rest between the locking element 15 and the support element 9.

[0051] The spring element 5 can be formed as a wire spring, as is the case in the present design example. In the present wire spring 5, the spring base 6 is a substantially semi-circular coil. This is followed by the spring legs 7, 8 extending approximately parallel to one another, in particular in the mounting device 4. An approximately U-shaped section 35 of the spring element 5 and/or the wire spring is formed by the semicircular coil and the spring legs extending in parallel. The free and/or open ends 19, 20 of the legs 7 and 8 are at least regionally angled relative to one another, in particular the free ends 19, 20 extend outward in the assembled position. Support regions 21 and 22 are also provided at the free ends 19, 20, by which the spring element 5 and/or the spring legs in their assembled state can—while in operation—support themselves against the brake system within the latter in order to enable the spring effect. The spring element 5 can approximately along its center have the transition from the U-shaped section 35 to the angled region of the legs 7, 8. In particular, the inventive backing plate 1 can have such a spring element 5, in particular a wire spring.

[0052] In this design example, the mounting device 4 is formed in a mirror-symmetrical fashion to a longitudinal center axis 16 of the backing plate 1. Both the common support element 18 for the spring legs and the locking element 15 and the support element 9 for the spring base in this case lie on this longitudinal center axis 16 in a mirror-symmetrical fashion, while the support elements 10 and 11 of the respective spring legs are separated by the longitudinal center axis 16 in a mirror-symmetrical fashion.

[0053] A detailed illustration of the mounting device 4 in a perspective view from the backing plate top side 17 is shown in FIG. 4. It can be seen in this case that the support element 9 for the spring base is arranged on the back side 3 of the backing plate 1 in the region of the backing plate bottom side 24. The locking element 15, which is provided with an alignment slant 23 that points away from the support element 9, is arranged adjacent to the support element 9 for the spring base. The spring base of a spring element to be inserted can be pushed over this alignment slant 23 such that the spring base can be securely positioned between the support element 9 of the spring base and the locking element 15. The locking element 15 ensures that an inserted spring element cannot be easily removed from mounting device 4. In addition, the support element 9 for a spring base can also still be provided with an undercut not incorporated here.

[0054] Furthermore, the illustration according to FIG. 4 clearly shows the two support elements 10 and 11 on the back side 3 of the backing plate 1. In the present design example, the support elements 10 and 11 each have an undercut 13, 14, into which the spring legs of the spring element come to rest when the spring element is inserted. The undercuts 13 and 14 ensure that the spring element is captively held in the inserted state in the mounting device 4 in cooperation with the locking element 15 and the support element 9 for the spring base. Lastly, FIG. 3 shows the common support element 18 (embodied in a cylindrical shape in the design example selected here) of the spring legs of the spring element.

[0055] FIG. 5 shows a further detailed illustration of the mounting device 4, this time in a top view of the bottom side of the backing plate bottom side 24. In this case, the front side 2 of the backing plate 1, onto which a friction pad can be applied, can now also be seen.

[0056] The illustration according to FIG. 5 clearly shows the undercuts 13 and 14 of the support elements 10 and 11 for the spring legs of a spring element. The support elements 10 and 11 are in this case formed such that they have a web 25, 26 that is substantially perpendicular to the back side 3 of the backing plate 1, followed by a region 27, 28 extending substantially parallel to the back side 3 of the backing plate 1. The undercuts 13 and 14 are formed such that their shapes are adapted to the profile or the cross-section of a spring leg of the spring element, which is round in cross-section. Such undercuts adapted to the shape of the spring legs result in a very good support effect of the support elements 10 and 11 as well as in a secure, captive arrangement of the spring element within the mounting device 4.

[0057] The insertion of a spring element 5 into the mounting device 4 of the backing plate 1 is now shown in FIGS. 2 and 3. The spring element 5, produced from a metal part or wire having a round cross-section, consists substantially of a rounded spring base 6, which is followed by parallel regions of spring legs 7 and 8. Support regions 21 and 22 are also arranged at the open ends 19, 20 of the legs 7 and 8, by which the spring element 5 and/or the spring legs in their assembled state can—while in operation—support themselves against the brake system within the latter in order to enable the spring effect.

[0058] As can be seen from FIG. 2, the insertion of the spring element 5 begins by positioning the spring base 6 between the common support element 18 and the respective support elements 10 and 11 of the spring legs 7 and 8, wherein the spring legs 7 and 8 are positioned opposite the common support element 18.

[0059] Subsequently, the spring element 5 is now displaced in the direction of the support element 9 for the spring base 6. The spring legs 7 and 8 are in this case positioned between their respective support elements 10 and 11. The spring element 5 is captively positioned within the mounting device 4 by now pushing the spring element 5 with its spring base 6 over the alignment slant 23 of the locking element 15 until the spring base 6 rests between its support element 9 and the locking element 15. While the spring base 6 is displaced on the alignment slants 23 of the locking element 15, a stress is built up within the spring element 5, which is again relieved when the spring base 6 is pushed over the alignment slant 23 and the locking element 15. The spring base 6 in this case springs into the space between the locking element 15 and the support element 9 of the spring base 6. The spring base 6 is therefore now securely and captively held in the mounting device 4 for the spring element 5 because the locking element 15 prevents the spring element 5 from retracting, while the undercuts 13 and 14 of the support elements 10 and 11 of the spring legs 7 and 8 make it impossible for the spring element 5 to pivot out of the mounting device 4.

[0060] In operation within a brake system, the spring element 5 can now support itself with its spring legs 7 and 8 under load on the common support element 18, wherein the backing plate 1 is thereby held in position. The spring element 5 is in this case adapted as a hold-down spring for the backing plate 1.

[0061] FIGS. 6 to 8 show a second design example of a backing plate 1 according to the invention, which essentially corresponds to the first design example of FIGS. 1 to 6. However, in contrast to the first design example, a further support element 29 and 30 is provided for the spring legs 7 and 8, respectively, which is arranged above the support and guide element 18 between the latter and the backing upper side 17. However, in contrast to the support elements 10 and 11 of the spring legs 7 and 8, the support elements 29 and 30 do not have undercuts. However, further exemplary embodiments are also conceivable, wherein the support elements 29 and 30 are also provided with undercuts.

[0062] In the design example of FIGS. 6 to 8, the support elements 29 or 30 with the respectively assigned support element 10 or 11, respectively, of the spring legs 7 and 8 are designed substantially aligned in reference to the longitudinal center axis 16 and mirror-symmetrically to the longitudinal center axis 16. Further exemplary embodiments can also provide that the support elements 29 and 30 have a larger or smaller distance with regard to the longitudinal center axis 16 than the support elements 10 and 11 and thus do not align with them, but still have mirror symmetry to the longitudinal center axis 16.

[0063] FIG. 9 shows a third design example of an inventive backing plate 1 that substantially corresponds to the second design example of FIGS. 6 to 8. However, in contrast to the second design example, no support element 18 is provided for the spring legs 7, 8.

[0064] FIG. 10 shows a fourth design example of the inventive backing plate 1 that substantially corresponds to the first design example according to FIGS. 1 to 5, although no support element 18 is provided for the spring legs 7, 8.

[0065] FIGS. 11 to 14 show a fifth design example of the inventive backing plate 1, wherein the backing plate 1, substantially manufactured from steel, in the present example comprises a mounting device 4 with four dimple-like projections 31 adapted as support elements, which are also referred to as dimples. A different number of dimples 31 is of course also conceivable. The dimples 31 are provided on the back side 3 of the backing plate 1. The spring legs 7, 8 are at least regionally abut the dimples 31. As can be further seen from FIGS. 11 to 13, this exemplary embodiment also provides support elements 29 and 30 for the spring legs 7, 8. FIG. 14 shows a cross-sectional representation through the centerline according to FIG. 11.

[0066] The sixth design example according to FIGS. 15 to 17 differs from the fifth design example in that the inventive backing plate 1 does not provide for lateral support elements 29 and 30 for the spring legs 7, 8. The backing plate 1, produced substantially from steel, has a plurality, in this case four, dimples 31 on which each spring leg 7, 8 rests at least regionally. FIG. 16 is a cross-sectional view according to the cross-section line 36 through the dimples 31 in FIG. 15, and an enlarged cross-section of the view according to FIG. 16 can be seen in FIG. 17.

[0067] As can be seen in particular from the enlarged illustration according to FIG. 17, the dimple-like projections 31 are formed as push-throughs and are therefore integral with the carrier plate 1.

[0068] The dimple-like projections or dimples 31, respectively, are produced by pressing through several circular dimples, for example with a diameter of approx. 6 mm, using a tool with a concave-shaped tip from the front side 2 of the carrier plate 1 such that a plurality of dimples 31 project from the carrier plate surface on the back side 3. In general, the ratio of the dimple diameter to the carrier plate thickness can be between 1 and 2, preferably slightly above 1.

[0069] In a second method step, a tool is pressed in the opposite direction against the projecting dimples 31 in order to split the dimples 31 in a further forming process and to form projections 32 with undercuts 33 from the dimples 31. A tool with a pyramidal tip can be used for this purpose, which facilitates the splitting of the dimples 31. Conical tip tools may also be used, but those with a pyramidal tip are preferred.

[0070] As can be further seen from FIG. 17, the strong undercuts 33, with which the friction pad can be anchored on the carrier plate 1 such that high shearing forces can be absorbed, are formed by splitting the projections 32. Circular recesses 34 remain on the front side 2 of the carrier plate 1, for example with a depth of 2 to 3 mm, the bottoms of which can have a convex curvature.

[0071] When pressing the friction pads onto the carrier plate 1, the friction material of the friction pad can penetrate the undercuts 33 and firmly anchor itself there.

REFERENCE NUMERALS

[0072] 1 Backing plate [0073] 2 Front side [0074] 3 Back side [0075] 4 Mounting device [0076] 5 Spring element [0077] 6 Spring base [0078] 7 Spring leg [0079] 8 Spring leg [0080] 9 Support element [0081] 10 Support element [0082] 11 Support element [0083] 13 Undercut [0084] 14 Undercut [0085] 15 Locking element [0086] 16 Longitudinal center axis [0087] 17 Backing plate top side [0088] 18 Support and guide element [0089] 19 End [0090] 20 End [0091] 21 Support region [0092] 22 Support region [0093] 23 Start-up slant [0094] 24 Backing plate bottom side [0095] 25 Web [0096] 26 Web [0097] 27 Region [0098] 28 Region [0099] 29 Support element [0100] 30 Support element [0101] 31 Dimple-like projections [0102] 32 Projections [0103] 33 Undercuts [0104] 34 Circular recesses [0105] 35 U-shaped section [0106] 36 Cross-section line